AeroWorks EXTRA 260 ARF-QB Assembly Manual Download Page 60

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Use a drop of blue Loctite on muffler bolts
before installation.

Install muffler cans using the supplied gasket
or high temp silicon gasket material and
securely bolt to cylinder heads as shown.

Side view of standard muffler installation.

Canister Muffler Installation

1. Gather the header and canister parts as shown:

1 - 50mm drop flex header (left)

1 - 50mm drop flex header (right)

2 - MTW-TD 110 Long canisters (Rear exit)

2 - Teflon couplers

4 - clamps

Summary of Contents for EXTRA 260 ARF-QB

Page 1: ...1 150cc EXTRA 260 ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 401 Laredo St Unit D Aurora CO 80011 www aero works net ...

Page 2: ...s and Stabs 11 Wing Assembly 14 Stab and Elevator Assembly 22 Rudder Rudder Servos and Tail wheel Assembly 28 Main Landing Gear Gear Cuff and Wheel Pant Assembly 43 Engine Muffler or Canister and Throttle servo installation 51 Fuel Tank Assembly and Installation 70 Ignition Module and Radio Installation 74 Cowl Installation 82 Manual Choke Installation 89 Final Cowl Assembly 91 Preflight Preparati...

Page 3: ...and workmanship at the date of purchase This warranty does not cover any component parts damaged by use or modification In no case shall Aeroworks liability exceed the original cost of the purchased kit Further Aeroworks reserves the right to change or modify this warranty without notice In that Aeroworks has no control over the final assembly or materials used for final as sembly No liability sha...

Page 4: ... through this assembly manual carefully before starting the as sembly of your new 150cc EXTRA 260ARF QB Inventory and inspect all parts and hard ware for any imperfections or damage Please notify Aeroworks immediately if there are missing or damaged parts INTENDED USE This plane should not be regarded as a toy This is an aerobatic plane and is recommended for pilots who are beyond the trainer stag...

Page 5: ...t washers 1 Canopy base painted installed on the fuselage by 4 4 40 blind nuts and 4 4 40x16mm hex style bolts 1 Tinted Canopy glued on the canopy base and painted 4 6 bonded washers for the mounting of the canopy base 4 3mm split lock washers for the mounting of the canopy base 2 3 5 o d x 1250mm Antenna guide tube installed 2 3 5 o d x 80mm rudder pull pull exit tubes installed Left Wing with Ai...

Page 6: ...16mm O D x 460mm Carbon stab tube Rear 4 8 32 x 25mm Hex head bolts for wing mounting 4 8 bonded washer for wing mounting 4 4mm split ring lock washers for wing mounting 4 4 40x16mm Hex style head bolts for stab mounting 4 6 bonded washer for stab mounting 4 3mm split ring lock washers for stab mounting 4 1 8mm cotter pins Second method wing mounting for security 6 6 4 40 2 1 2 Two end threaded pu...

Page 7: ...00mm Silver 881 Small repairs 1 600x300mm Transparent covering Sealing hinge gaps 2 2500x20mm Transparent covering strip Sealing wing and stab leading edges 11 24 6 35mm machined aluminum engine stand offs 12 1 AW Custom throw meter measure control surface deflection 13 1 Custom Vinyl Decal Set 14 1 Assembly manual with picture folders on CD ...

Page 8: ... 3 Rudd x 11 Y harness 2 x 6 2 x 18 2 x 24 2 x 36 2 x 48 2 Receivers PCM 2 x Receiver battery min 6 0 volt 1700ma 1 x Ignition battery min 4 8 volt 1700ma Tools Allen wrenches US and Metric Dremel cutting disc and sanding drum tool Electric drill and selection of bits Flat head screwdriver Hobby heat gun Hobby iron with protective sock Masking tape Modeling knife Needle nose pliers or crimping too...

Page 9: ...t Reduce heat and work slowly IMPORTANT Go over any and all seams and color overlaps with your iron to assure good adhesion of the covering to the wood This is especially im portant at the leading edges of the wings and stabs 3 If bubbles persist use a small pin to punch holes in the bubble to relieve trapped air and reheat 4 Use your heat gun with extreme caution Take care not to apply too much h...

Page 10: ...inge gaps Use covering iron to seal the clear covering snugly into the bottom of the hinge lines as shown for air tight hinge seals Note The clear covering does have a transparent protective backing This must be removed prior to applying heat and to the surface IMPORTANT It is the responsibility of the purchaser operator to check the covering seams and overlaps for security and a good seal Aerowor...

Page 11: ...nsure a clean surface for the covering to stick to Note Wing pictured in the following steps may be a different color and model However the procedure for applying the clear covering to your model will be the same 3 Seal the top and bottom of the leading edge carefully to insure the covering is securely attached to the wood underneath 4 Lay out one of the pieces of covering next to the leading edge...

Page 12: ... stabs later 7 Remove the clear backing from the covering Note Do not skip this step There is a backing to the covering Take time to remove this backing to get the correct adhesion to the already applied covering 8 Begin by tacking the covering in place at the wing root Pay close attention to insure that the covering is centered top and bottom on the lead ing edge of the wing ...

Page 13: ... Clear covering is centered on trim colors Using the same method complete the remaining wing and stabs IMPORTANT It is the users responsibility to check the covering seams and overlaps for security and a good seal Aeroworks is not responsible for failure of covering seams or overlaps during flight This is a never ending process that must be done after each flying secession Due to varying tempera t...

Page 14: ...as shown below to begin the servo installation Note 6 extension will also be needed per wing when connecting aileron servos to receiver WING ASSEMBLY 2 Layout the servos extensions and Y harness on the wing to test fit the installation and ensure servo leads are the correct length Minimum recommended servo 180 in oz Metal geared Digital 3 Attach the 36 extension to the outboard servo lead and secu...

Page 15: ...e servo wire through the wing without hanging up inside the wing 7 Draw the 36 servo extension of the outboard servo through the wing and pull through the wing root rib as shown 8 Repeat this process for the middle servo using the 24 extension Then repeat the process using the servo lead from the inboard servo When finished there should be a lead from each servo extending out of the wing root rib ...

Page 16: ...re all Y harness connections with safety wire string tape or other method Ensure the connectors will not come apart from vibration or light tension Secure excess wire from Y harness and extensions inside the wing root rib using tape or Velcro as desired 11 Install all three servos in servo wells with the output shaft toward the leading edge of the wing Mark locations of servo mounting holes Use a ...

Page 17: ...shown The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut IMPORTANT The ball link for the root end control horn goes in the bottom hole of the horn The ball link for the middle horn goes in the center hole of the horn The ball link for the tip end horn goes in the top hole of the horn This gives the correct offset to eliminate bind ing...

Page 18: ...rns over the factory drilled holes 6 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly 7 Align the left and right sides of the control horns to the mounting holes and secure using six wood screws as shown ...

Page 19: ...ervo arms are parallel to the aileron hinge line Ensure all servos do not fight each other at center or either end point at full deflection Take advan tage of servo programmers and match boxes available today to achieve best results This will help keep servos from binding and causing possible aileron flutter 2 Wrap masking tape around carbon tube for marking the cut location 3 Mark cut location on...

Page 20: ...lp prevent ends from splitting 6 Remove the 4 40 ball link and lock nut from the pushrod Note Make sure lock nut against servo arm ball link is tight so pushrod length will not change 7 Slide carbon reinforcing tube over the 4 40 pushrod and reassemble ball link to pushrod end Note Make sure lock nut against servo arm ball link is tight so pushrod length will not change ...

Page 21: ...21 8 Final pushrod assembly shown below 9 Repeat all the above steps for installing the aileron servos into the other wing panel ...

Page 22: ...r vos 2 per stab required one 11 Y harness and one 48 servo extension Note 48 servo extension will be used to connect servos to receiver during a later step STAB AND ELEVATOR ASSEMBLY 2 Install servos in servo wells with the output shaft toward the leading edge of the stab Fish the servo leads through the stab and out of the stab root rib as shown 3 Mark locations of servo mounting holes Use a 1 1...

Page 23: ...ow There are 2 pushrods 4 ball link assemblies 2 brass spacers 2 left and 2 right side control horns and 12 wood screws per stab and elevator Note There is also a Carbon tube for reinforcing the pushrod not pictured This will be installed during a later step 8 Assemble two pushrod and control horn as semblies as shown The ball link goes be tween the left and right sides of the control horn sides a...

Page 24: ...the three control horn holes However it is very important that you use the same hole for each control horn We recommend you use the middle or bottom hole to achieve desired 3D throws and top hole if you prefer more precision or I M A C style flying 12 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly ...

Page 25: ...rm is parallel to the ele vator hinge line A 1 1 2 servo arm is recom mended to achieve full deflection of the eleva tor bevel 16 Ensure the servos do not bind at center or either end point at full deflection Take advantage of servo programmers and match boxes available today to achieve best results This will help keep servos from binding and causing possible elevator flutter Carbon Reinforcement ...

Page 26: ... cut location onto carbon tube Carbon tube should fit between 4 40 ball link lock nuts Note Make sure lock nuts are tight so pushrod length does not change 6 Remove the 4 40 ball link and lock nut from the pushrod Note Make sure lock nut against servo arm ball link is tight so pushrod length will not change 5 Remove the 4 40 ball link from the control horn ...

Page 27: ...the above steps for installing the elevator servos into the other stab 7 Slide carbon reinforcing tube over the 4 40 pushrod and reassemble ball link to pushrod end Note Make sure lock nut against servo arm ball link is tight so pushrod length will not change ...

Page 28: ...res no epoxy gets into the hinge during assembly 3 Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre drilled holes in the trailing edge of the fin Apply epoxy to one side of each hinge and insert the hinge completely into the hole 4 Ensure the hinge axis is vertical and parallel to the trailing edge of the fin before epoxy cures Wipe away excess epoxy with alcohol w...

Page 29: ...th alcohol wetted wipes 7 Ensure there is minimal to no gap between fin and rudder Allow epoxy to fully cure Note Ensure you have full rudder deflection before epoxy fully cures Rudder Servos Installation 1 Gather the rudder servos min 180 in oz and a 11 Y harness as shown below Note If using higher Torque min 300 in oz Digital Metal geared servo only two servos are required This is the installati...

Page 30: ...and use a 1 16 bit to drill the rudder servo mounting holes 3 Install the aft rudder servo with the output shaft forward Pull the servo lead and Y har ness up through the forward servo cutout At tach the Y harness to the forward servo rudder servo leads and secure with safety wire string tape or other method Ensure the connectors will not come apart from vibration or light ten sion Push the servo ...

Page 31: ...er servo arm coupler hardware as shown below There are 4 4 40 ball links with hardware 2 4 40 all thread rods and 2 car bon sleeves Note Rudder coupler hardware is Not Supplied 2 Thread the threaded rods into the ball link as shown 3 Slide the carbon sleeve over the threaded rod as shown ...

Page 32: ... use a minimum of 3 to 3 1 2 servo arms 6 Install the rudder servo output arms on the rud der servos as shown Adjust the length of the rudder coupler rods so that the rudder output arms are at the centered position Ensure both servos do not fight each other at center or either end point at full deflection Rudder Pull Pull Cable Installation 1 Gather the rudder control linkage parts shown below 2 R...

Page 33: ...rd the front Repeat on other side 3 Pull the rudder cables from the fuse tail to the rudder servo tray 4 Insert rudder cable through the brass swage tube then through the threaded coupler hole and back through the brass swage tube as shown 5 Loop the cable back through the brass swage tube as shown ...

Page 34: ... off excess cable as shown 7 A drop of thin CA may be applied to the swage tube to help secure the cable 8 Attach a 4 40 ball link to each threaded cou pler 9 Repeat above steps for the other side rudder cable 10 Attach the ball links to the aft rudder servo arm using the supplied brass spacers 4 40 bolts and locknuts ...

Page 35: ...eft and 2 right side control horns Assemble the ball links between the control horns as shown Secure with nylon lock nut Note Mount ball link to bottom control horn hole to obtain full rudder deflection 2 Align the control horns over the factory drilled holes 3 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly ...

Page 36: ... 5 Remove the ball link from the rudder control horn 6 Screw threaded coupler halfway into ball link and reinstall the ball link onto the rudder con trol horn with the 4 40 bolt and locknut 7 Plug the rudder servo Y harness into the rud der channel of the receiver and power up Turn on transmitter to center rudder servos ...

Page 37: ... swage onto rudder cable Next thread the rudder cable through the threaded coupler and back through the brass swage tube on both sides With the rudder servos powered up and centered pull light tension on the cable through the coupler on both sides as shown 10 Loop the cable back through the brass swage tube as shown 11 Pull the loop through the coupler until it is approximately 1 2 long ...

Page 38: ...rimping tool or pliers 13 Hint If additional crimping is needed a small C Clamp may be used for additional crimping pressure 14 Cut off excess cable as shown 15 A drop of thin CA may be applied to the swage tube to help secure the cable ...

Page 39: ...vos do not fight each other at center or at either end point Note Using a rubber band around the cables close to the servo arms will help eliminate any cable slop Tail Wheel Installation 1 Gather the tail wheel parts shown below Carbon Tail wheel strut 3 tail wheel mounting screws aluminum steering tiller 2 tiller mount ing screws and 2 steering springs 2 Place tail wheel steering tiller over the ...

Page 40: ... on tail wheel strut mounting screws before inserting in the pre drilled mounting holes on the bottom rear of the fuse 5 Mount the tail wheel strut using three wood screws 6 Attach the steering spring to one side of the rudder tiller Center the spring between the rudder and tail wheel tiller ...

Page 41: ...e spring and insert through the tail wheel tiller 9 Use pliers to twist spring ends closed around the tail wheel tiller 10 Cut off excess spring wire as shown 11 Repeat for opposite side tail wheel spring Adjust length and spring tension so that tail wheel is centered when rudder is centered ...

Page 42: ...42 12 Tail wheel final assembly is complete ...

Page 43: ...ies 2 wheel pants and landing gear mounting hardware MAIN LANDING GEAR GEAR CUFF AND WHEEL PANT ASSEMBLY 2 Gather the landing gear strut 4 8 32 bolts 4 lock washers and 4 flat washers 3 Remove the landing gear cover by removing the two bolts on the bottom of the cover 4 Lift out the landing gear cover after removing the two mounting bolts ...

Page 44: ...e fuse 6 Assemble the landing gear bolts with lock washer and flat washer Use a drop of blue Loctite on landing gear bolts before attaching the landing gear 7 Bolt landing gear strut to fuse with 4 bolts and washers Ensure tapered edge of the gear strut is facing toward the rear 8 Reinstall the landing gear cover ...

Page 45: ...efore attaching the cover 10 Reinstall both landing gear cover bolts with Loctite and fasten firmly 11 Gather the landing gear cuffs mounting bolt flat washers and lock washers Note There is a right and left gear cuff 12 Slide the gear cuff onto the proper gear strut ...

Page 46: ...g side showing incorrect fit If this is what you see install the cuff on the other side of the landing gear strut for proper fit 15 Slide the lock washer then the flat washer on the cuff mounting bolt Use a drop of blue Loctite on each bolt before installing the bolt 16 Install left and right gear cuffs as shown ...

Page 47: ...n below 2 wheels 2 axle assemblies 2 wheel pants 4 mounting bolts 4 flat washers and 4 lock washers 2 Install the axle into the gear strut with nylon lock nut Optional Use a drop of blue Loctite on the wheel axle bolt before assembly 3 Use two wrenches to screw the lock nut on the wheel axle Note Do not tighten axle securely yet ...

Page 48: ...l and tighten the wheel pant mounting bolts to hold the wheel pant in place Note DO NOT use Loctite at this time 6 Now tighten the axle nut against the landing gear strut with a small wrench while using the wheel pant slot to hold the flat sides of the axle bolt in alignment Tighten the lock nut enough so that the axle bolt will not rotate during final tightening 7 Now remove the wheel pant mounti...

Page 49: ...sure flat sides of axle bolt are still vertical and aligned with wheel pant 10 Install the inner wheel collar on the axle Use a drop of blue Loctite on the wheel collar set screw and tighten the wheel collar in place 11 Install the wheel and outer wheel collar Use blue Loctite on the wheel collar set screw be fore final tightening ...

Page 50: ...sher then the flat washer on the wheel pant mounting bolts Use blue Loctite on the bolts before final tightening 13 Final installation of wheel pant with two mounting bolts 14 Repeat above steps for other wheel and wheel pant ...

Page 51: ...ine mounting template for the DA 150 Note If other engines are used the templates may be modified to fit you engine selection Center your engine over the laser marked thrust lines on the template Mark and drill the engine mounting hole locations for your engine Follow the next steps for mounting your engine 3 Line up the template with the pre marked firewall thrust lines Mark the location of the e...

Page 52: ...p cover 7 Machined 6mm aluminum spacers are in cluded to set the proper stand off distance for the engine used 8 Use 2 aluminum spacers behind the DA 150 to ensure adequate standoff from firewall We recommend using flat fender washers not supplied between the spacers and the front of the firewall to distribute bolt pressure to the plywood firewall ...

Page 53: ...t spacers and washers Use flat fender washers not supplied between the spacers and fire wall to distribute bolt pressure Insert the bolts through the firewall and add fender washers and lock nuts to secure 11 Tighten firmly Use Loctite to secure Throttle Servo Installation 1 Remove the 4 screws from the bottom of the engine box cover and remove the engine box bottom cover ...

Page 54: ...ottle pushrod to the engine throttle arm as shown Layout the loca tion of the throttle servo and throttle pushrod as shown Ensure the servo and pushrod do not interfere with the canister muffler headers 4 If standard style muffler cans are to be used install the standard muffler cans to the engine cylinder heads as shown Attach the throttle pushrod to the engine throttle arm as shown Layout the lo...

Page 55: ...or use masking tape to protect from any debris getting into the carburetor or cylinders 7 Insert the throttle servo into the servo cutout with the servo output arm toward the throttle pushrod as shown 8 Mark and use a 1 16 drill bit for the servo mounting screws 9 Mount the throttle servo using servo mounting screws ...

Page 56: ... the carburetor at half throttle measure and mark the end of the throttle pushrod wire that will be inserted into the threaded coupler as shown 12 Cut the throttle pushrod to the proper length 13 Gather the soldering tools as shown below Note For best results we recommend a high quality Silver Solder like Sta Brite silver solder ...

Page 57: ... closed or full open positions 16 A none soldering method of attaching throttle pushrod is shown in the following steps Hardware for this method is not supplied Gather 2 4 40 ball links 1 brass spacer 4 40 all thread and carbon tube 14 Solder the threaded coupler to the throttle pushrod wire Note Lightly sand end of rod for best bond 17 Attach 4 40 ball link and threaded rod to throttle servo arm ...

Page 58: ... threaded pushrod 19 Install the throttle pushrod to the engine throttle arm as shown 20 Place the bottom engine box cover over the pushrod and mark the location of the throttle pushrod exit on the cover 21 Use a rotary cutting tool or hobby saw to cut out the pushrod exit slot as shown ...

Page 59: ...s necessary 23 Reinstall the bottom engine cover with the 4 screws as shown 24 Place a drop of CA glue on the throttle servo mounting screws from inside the engine box to prevent loosening from engine vibration Standard Muffler Installation 1 Gather the standard muffler parts as shown Shown DA150 C Compact muffler set Also fits DA150 Standard muffler set ...

Page 60: ...igh temp silicon gasket material and securely bolt to cylinder heads as shown 4 Side view of standard muffler installation Canister Muffler Installation 1 Gather the header and canister parts as shown 1 50mm drop flex header left 1 50mm drop flex header right 2 MTW TD 110 Long canisters Rear exit 2 Teflon couplers 4 clamps ...

Page 61: ...ring from the canister tunnel pre cut air exit holes 4 Covering removed from two air exit holes just aft of the landing gear 5 Use a hobby knife to remove the covering from the bottom of the fuse between the second and third formers aft of the landing gear as shown Note If using standard mufflers skip the following steps and go to fuel tank installation Page 70 ...

Page 62: ...n 7 Gather the included pre cut balsa canister tun nel baffles lite ply canister mounts and sili cone tubing as shown below 8 Dry fit the larger aft tunnel balsa floor baffle and trim as necessary Apply medium CA glue to baffle and install 9 Install the aft tunnel balsa floor baffle as shown ...

Page 63: ...r baffle as shown 12 Gather the two supplied silicon tubes for making the vibration isolation mounts Mark eight 7 8 pieces onto each tube Note The silicon tubing may have already been pre cut for you if so skip this step 13 Cut 16 7 8 pieces of the silicon tubing as shown Note The silicon tubing may have already been pre cut for you if so skip this step ...

Page 64: ...t former behind the air exit holes Apply thick CA or epoxy and glue in place 16 Ensure the aft canister mounting former is flush with the inside fuse sides as shown Apply CA glue to all edges to secure former in place 17 Dry fit the front canister mounting former to fit in front of the first former behind the motor box firewall Apply thick CA or epoxy glue and glue in place ...

Page 65: ...canister mounting formers are flush with the inside of the fuse sides as shown 20 Insert canisters from rear through the canister mounting formers 21 Rotate canisters as necessary to get the stinger exhaust pipes through the rear former and out the air exit holes ...

Page 66: ...ng formers with the stinger exhaust pipes exiting through the air exit holes shown below 24 Slip the Teflon couplers onto the drop headers and place the spring clamps on the Teflon cou plers Next slip the Teflon couplers onto the front of the canisters as shown 25 Use pliers to spread the spring clamps and slide them to properly clamp the Teflon cou pler to the headers and the front of the caniste...

Page 67: ... ports on the cylinders as shown 27 Install the header pipes to the engine using blue Loctite as shown Note Use a gasket to ensure good seal 28 Firmly tighten the header mounting screws to the engine 29 Proper alignment of canisters and headers from bottom view ...

Page 68: ...m rear view 31 Proper alignment of canisters and headers from front view 32 Dry fit both sides of the aft canister tunnel baffle to fit behind the former just aft of the canisters 33 Apply CA glue to each half of the aft tunnel baffle and glue in place ...

Page 69: ...e aft rear tunnel baffle glued in place behind the former 35 Use supplied covering material to recover the access hole in the bottom of the fuse as shown 36 Final installation of canister mufflers and headers from bottom view ...

Page 70: ...e pick up This will keep the weight of the fuel clunk from pulling the fuel line off the brass tube Barbs are Supplied 3 Insert the rubber stopper into the tank with the vent tube at the top of the tank Secure the stopper with set screw Take care not to strip threads by over tighten set screw Fuel Tank Installation 1 Gather the fuel tank parts as shown below Fuel tank fuel tubing foam rubber fuel ...

Page 71: ...ylon tie mounting holes 3 Install the foam rubber and nylon ties for mounting the fuel tank 4 Cinch the nylon ties securely to hold the tank against the foam on the fuel tank floor 5 Cut off excess nylon tie material after tank is firmly installed Note If you are not using canister mufflers and have not sheeted the underside of the tank floors it is not necessary to mark and drill the mounting hol...

Page 72: ...w the fuel dot to interfere with the leading edge of the wing Note The higher you mount the fuel fill dot the less fuel will siphon out when fueling 8 Mark and drill the fuel vent exit hole on the bot tom of the fuse Cut off excess fuel line as shown Note We have supplied rubber grommets for you to route the fuel line through to give a finished professional look 9 Route the line to the engine carb...

Page 73: ...73 10 Connect the fuel line to the engine carburetor intake nipple and secure with small nylon tie ...

Page 74: ...pads as shown IGNITION AND RADIO INSTALLATION Ignition Module Installation 2 Gather the ignition module and mounting hardware as shown 3 Position the ignition module inside the engine box to allow both of the spark plug leads to exit and properly connect to the engine without excess tension or chafing 4 Mark the location for the nylon tie holes ...

Page 75: ...4 layer pad as shown Make the pad slightly larger than the ignition module as shown 7 Install the ignition module and the foam pad with a nylon tie as shown 8 Secure the ignition timing connectors with safety wire string tape or other method Ensure the connectors will not come apart from vibration or light tension ...

Page 76: ...on 1 Gather the switches to be mounted as shown below We used one switch for the ignition and one switch for each receiver 2 Fit the wing to the fuselage and check that switch location will not interfere with the mounting of the wing Mark the location of the wing leading edge on the fuse to avoid conflict with the switch mounting location ...

Page 77: ...ounting plate for a template 4 Use a rotary cutting tool or a hobby knife to cut out the switch mounting holes 5 Mark the location of the wing leading edge on the fuse to avoid conflict with the switch mounting location 6 We chose to mount the other radio switch on the right side Mark location for the switch using the switch mounting plate for a template ...

Page 78: ...gulator 1 Gather the ignition battery and regulator if used as shown 2 Roll the supplied foam rubber to make a 4 layer pad as shown Make the pad slightly larger than the ignition battery as shown 7 Mount switches in accordance with the switch manufacturers instructions and hardware ...

Page 79: ...ound the ignition battery and foam pad and secure to fuse floor as shown 5 Trim excess Velcro tie wrap as shown 6 Ignition battery secure to fuse 3 Insert the Velcro tie wraps under the fuse floor for mounting ignition battery as shown ...

Page 80: ...ators as shown below 2 Mount the receivers batteries and regulators as shown below using the same steps and techniques as the ignition battery and regula tor Push receiver antenna all the way into the pre installed receiver antenna guide tube 7 Secure the battery connectors with safety wire string tape or other method Ensure the con nectors will not come apart from vibration or light tension ...

Page 81: ...e the remaining receiver antenna wire to the radio mounting tray as shown This will prevent the antenna wire from vibrating back out 6 Attach all servos battery regulator and switch leads to the proper connectors A typical radio installation is shown below 3 Apply baby powder or corn starch to antenna wire to assist getting it into the guide tube ...

Page 82: ... en gine cylinder heads if desired 3 Additional balsa sheeting may be added to the top cowl baffle to extend the baffle to the cylin der head if desired Always check the operating temperature of your engine to prevent any damage from occurring Aeroworks is not responsible for damages incurred from improper engine cooling Cowl Preparation For Standard Style Mufflers see step 1 page 88 for canister ...

Page 83: ...p down with a T pin 3 Tape the template to the bottom of the fuse with the back edge of the template flush against the aft edge of the recessed cowl mounting ring Mark the center of the cowl former on the template as shown 5 Remove the template Using a hobby knife or small drill bit enlarge the holes to accommo date the 4 40 cowl mounting bolts ...

Page 84: ... 7 Mount the template to the bottom of the cowl mounting tabs with two cowl mounting bolts and rubber backed washers as shown 8 Lift the template so that it contacts the bottom of the muffler exhaust stacks Trace the location of the exhaust stack exit holes 9 Exhaust stack holes traced onto the template ...

Page 85: ... cowling to slip over the stacks 11 Allow a 1 4 clearance around the outside edge of the exhaust stack tubes 12 Use a hobby knife to cut out the exhaust stack holes in template 13 Trial fit the template until the proper size holes are achieved Do not forget to account for the curve at the bottom of the cowl ...

Page 86: ...eas prior to using any type of paint remover rubbing alcohols or cleaners to remove any pen lines 15 Use a rotary cutting tool and sanding drum to cut the exhaust stack exit holes as needed Note Take care not to cut or scratch cowl 16 Exhaust stack holes cut into bottom of the cowl 17 Trial fit the cowl until the proper size holes are achieved ...

Page 87: ...t the hot air exit hole 20 Mark the hot air exit hole using the template Note Take care and test painted areas prior to using any type of paint remover rubbing alcohols or cleaners to remove any pen lines 21 Use a rotary cutting tool file and sandpaper to cut out and smooth the edges of the cooling openings in the bottom of the cowl as shown Note Take care not to cut or scratch cowl ...

Page 88: ... allow for more exit air cooling for your engine to run at its recommended operating temperature Always check the operating temperature of your engine to prevent any damage from occurring Aeroworks is not responsible for damages incurred from improper engine cooling Cowl Preparation for Canister mufflers 1 Cowl installed with canister muffler installa tion 2 Gather the cowl and provided air exit h...

Page 89: ...bing alcohols or cleaners to remove any pen lines Manual Choke Pushrod Installation 1 Gather the choke pushrod and ball link shown below 2 Attach the ball link to the engine choke control arm With the top of the cowl removed pro ject a line from the ball link threaded hole slightly down and forward toward the lower front of the cowl This will be the approximate location for the exit hole for the c...

Page 90: ...ired to extend out of the front of the cowl when the choke control arm is fully pushed aft 5 Make a 90º bend at the end of the choke pushrod as shown 6 Reattach the lower cowl with the choke push rod extending through the hole Check for proper operation of the choke Ensure the pushrod does not bind at either choke on or choke off position ...

Page 91: ...91 Final Cowl Assembly 1 Use a drop of blue Loctite on each cowl screw prior to assembly 2 Firmly tighten each cowl screw through the top and bottom of the cowl and to the fuse as shown ...

Page 92: ...fuse or wing root wood 3 Gather the 4 4 40 stab mounting bolts and 4 6 small rubber backed washers 4 Slide the stab tubes in the fuse stab tube sleeves short tube front long tube rear Slide the stabs on the stab tube and plug in the elevator servo connectors Slide the rubber backed washers on the stab mounting bolts and insert bolts through the stab mounting tabs and into the fuse blind nuts Tight...

Page 93: ...g bolts and 4 6 small rubber backed washers Note It is highly recommended you apply thin CA glue to the front hold down dowels This is a High vibration area and can loosen the front dowels Always check the front dowels are secure before each flying session 8 Slide the rubber backed washers on the hatch mounting bolts and insert bolts through the hatch mounting holes and into the fuse blind nuts Ti...

Page 94: ... hobby knife plastic squeegee or credit card Windex or Application fluid like Rapid Tac Also a solution of 1 drop of dish detergent to a cup of water sprayed on the model will as sist in proper positioning Note Clean surface and tighten all covering before any decals are applied DECAL INSTALLATION 2 Factory placement of decals 3 Factory placement of decals ...

Page 95: ...95 4 Factory placement of decals shown ...

Page 96: ...ill be reused DO NOT throw away any transfer tape until decal placement is complete Decals supplied with the kit may vary from the photos below Decal application steps will be similar 6 Remove backing from Clear transfer tape 7 Apply clear transfer tape over top of decal ...

Page 97: ...ransfer tape to top of decal 9 Peel backing from decal 10 Spray model surface with application fluid Windex or soapy water solution 11 Spray back side of decal with application fluid Windex or soapy water solution ...

Page 98: ... decal smooth and remove all excess application fluid Let decal set until dry enough to be able to remove transfer tape with out removing decal Do not leave until completely dry or transfer tape will be difficult to remove 14 Pull transfer tape from top of decal Take care not to pull away or damage decal 15 Let decal dry before applying top decal ...

Page 99: ...y and centered on bottom decal Press top decal onto bottom decal and squeegee out excess application fluid Let decal dry until transfer tape can be lifted without removing decal 18 Pull transfer tape from top of decal Take care not to pull away or damage decal 19 Finished decal installation Work slowly and carefully and you will be rewarded with a beautifully finished model ...

Page 100: ...g style in small steps especially when shifting the CG toward the tail Move the battery or add small stick on weights to the nose or tail as necessary Note If additional nose weight is necessary we rec ommend moving the engine forward slightly by adding extra spacer or washers to move the C G forward Try this before adding an addi tional weight 4 For aerobatic flying a more aft balance point is be...

Page 101: ... Rudder throw measured in inches from the rudder boost tab 4 Use the supplied flight control deflection me ter to measure the throws in degrees It is recommended you level the model as shown 5 Elevator throw measured in degrees Locate throw meter at widest point of the elevator ...

Page 102: ...ator throw is recommended to give the pilot the same stick feel in either upright or inverted flight For 3D flying use the following throws 3D Rate Aileron 4 1 4 or 35 up 4 1 4 or 35 down Rudder 4 left 4 right Full rudder deflection is typically recommended for all out 3D Elevator 4 1 2 or 45 up 4 1 2 or 45 down Recommend Expediential 15 expediential on low rates 30 expediential on high rates 60 e...

Page 103: ...bolts hatch bolts servo screws control horn bolts wheel collars and clevis keepers are tight and secure Use Loctite were necessary Covering Check all seems and overlaps are se cure and have not lifted If any air gets under neath the covering it may pull the covering away form the plane and can cause the model to crash Always check before each flight A roll of clear tape in you flight box can be us...

Page 104: ...Here is a list of some of the more popular aerobatic and 3D maneuvers you can try Loops and rolls Knife edge flight Stall turns Snap rolls 2 4 and 8 point rolls Slow rolls Spins upright and inverted Flat Spins upright and inverted Harriers upright and inverted Water falls Torque Rolls Rolling circles Rolling harrier The sky and your imagination are you only limits FLY and ENJOY AEROWORKS World Cla...

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AeroWorks EXTRA 260 ARF-QB, Assembly Manual

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